I'm freaked out!!! This morning when trying to start my 94 Z28 143,000 miles (new battery). I turned the ignition and only got a jolt every time. I've had this problem before and tightened the connection on the battery and it then started. I have noticed for the past couple of months that when I would try to start it...it turned just a tad slowly and would then fire up. Once I got to work I smelled a slight burn of electrical, sort of light that of a train set or something (very slight but never smelled it before) Fast forward to leaving work and I turned the ignition and heard the loudest grinding noise. At first it sort of sounded like when you crank the ignition and the car is already running but immediately sounded like a continuous horrible grinding noise (WTF) Needless to say, can't get it started and didn't want to turn the ignition again. My car is an automatic. Someone please tell me that this won't cost over $500.00 lol!

 

Sorry but your starter is cooked. Take it to a reputable parts store. NOT Advance or AZ. and have it tested.

 

Just a word of warning, since a "bench test" involves only applying batt voltage to the starter to see if it spins (which you know it does based on your description of all the loud grinding noise which means the starter is spinning and the gear is at least starting to engage) then the real problem with the starter is one of a few things:
1) The one way rotator cuff is bad (allows the starter to push the motor but not allow the motor to push the starter)
2) The solenoid that pushes the starter gear is weak or stuck and is moving (test passed) but not fully reaching the flywheel
3) Your flywheel or starter teeth are stripped off
4) Loose starter bolts
5) Broken flywheel

I've personally had a problem with #1 on a brand new starter and had to sit under the car and watch the starter engage and attempt to crank (Scarry) then had to argue with Murrays to explain the problems with the "bench test" and how it doesnt check torque load to the starter in any way and just checks to see if it will react to 12v.

Seen #3 and #4 in auto's class in high school, both sounded ok once actually started.